Engineering Bulletin #102 front cover - PALMOILISpalmoilis.mpob.gov.my/publications/POEB/poeb113.pdf · palm oil engineering bulletin no. 113 1 engineering bulletin #102 front cover

PALM OIL ENGINEERING BULLETIN NO. 113 1

Engineering Bulletin #102

front cover

LEMBAGA MINYAK SAWIT MALAYSIAMALAYSIAN PALM OIL BOARD

KEMENTERIAN PERUSAHAAN PERLADANGAN DAN KOMODITI MALAYSIAMINISTRY OF PLANTATION INDUSTRIES AND COMMODITIES, MALAYSIA

Website: www.mpob.gov.my

ISSUE NO. 113 (Oct. - Dec. 2014)


EDITORIAL BOARD

ChairpersonDatuk Dr Choo Yuen May

MembersDr Lim Weng SoonAb Aziz Md Yusof

SecretaryIr N Ravi Menon

Malaysian Palm Oil BoardMinistry of Plantation Industries and Commodities,

Malaysia6 Persiaran Institusi, Bandar Baru Bangi,

43000 Kajang, Selangor, Malaysia.Tel: 603-8769 4400Fax: 603-8925 9446

Website: www.mpob.gov.my

© Malaysian Palm Oil Board, 2014All rights reserved.

No part of this publication may be reproduced, stored in a retrieval system, in any form or by any means, electronic,

mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher.

Products and services advertised in thisPalm Oil Engineering Bulletin do not

connote endorsement by MPOB.

Editorial

see page 2

CONTENTS

Editorial

TRAINING AND SEMINARSMPOB Training Programme 2015

MPOB Conferences and Seminars 2015

FEATURE ARTICLESMalaysia’s Entry to Ultra Supercritical Boiler Technology Club

A Critical Look at the Palm Oil Operations

TITBITS

DATASHEET Power Generation Plants in Malaysia

1

9

13

10

T

25

39

45

he process control department of the palm oil mill does not seem to have undergone any novel

transformation. In order to obtain accurate laboratory values of the many parameters that the mill will need to conduct process control in an acceptable way, there are many areas to look at. It may look simple to churn out any mill process control data but in order to generate true and useful data for process control, considerable care and preparations are necessary. This department is multifaceted and is heavily depended on: (1) sampler integrity, (2) sampling frequency, (3) sampling points, (4) sample size, (5) sample preservation, (6) sample analysis, (7) computation method, (8) computation accuracy, (9) instrument reliability and (10) analyst’s integrity. If any of the 10 items listed here is erratic in the analysis of a particular item the whole data generation related to that item become worthless and this can go on for a long time without detection. Some companies have counterchecks carried out by another audit body stationed at the Head Office or round robin audits by an outside body. But some small groups not only do not have such counterchecking arrangements but also do not conduct any laboratory analysis at all as they think it is a waste of time and money!

If out of the 10 items listed above the sampling was erratic, the sampler’s integrity will become questionable and every data generated become useless. I have personally experienced once the sampler integrity issue. When I stumbled upon a large quantity of mesocarp fibre samples piled up in the laboratory floor and when I asked what it was doing there the sampler quite innocently told me that they were the future samples for the following week! This can be expected as nobody would like to go every 2 hr to take samples from the press station, where the atmosphere is hot. Perhaps, in such

PALM OIL ENGINEERING BULLETIN NO. 1132

from page 1

CALL FOR ARTICLESPersonnel of the palm oil mills are invited to send in articles of relevance to the palm oil industry in Malaysia for publication in Palm Oil Engineering Bulletin. By sharing your expertise you will be helping the industry and the nation as a whole. The topics of interest are:

1. Plant modifications done in your mill that resulted in improvements in milling operation or main-tenance.

2. Innovations done in your mill that produced improvements in the operation of the mill and that you are willing to share them with others.

3. Any special work done in your mill that directly resulted in improvements in OER and product quality.

Please submit your article to us and we shall be pleased to publish them in Palm Oil Engineering Bulletin. Feel proud to have your articles published in this Bulletin that is circulated throughout the industry and MPOB offices worldwide.

cases, the sampling can be done by the press operators but he will like to take the samples from top of the press screw instead of from the bottom section and that certainly would not give the correct samples.

It is also possible for the process personnel to influence the laboratory personnel to record readings that look good. There can be innumerable flaws when human beings are

involved. In order to get the correct readings that truly reflects the process efficiency, it is necessary to completely change-over to automatic sampling, analysis and recordings system. With the advent of near infrared (NIR) analysis, that is capable of hundreds of analysis per minute, the palm oil mill process control operation can be conducted in a more accurate way with no room for human error or fraud. This will pave the way for mill modernisation in a big way as it will address all the 10 items listed above.


Training & Seminars

MPOB TRAINING PROGRAMME 2015

A1.2 Intensive Diploma in Oil Palm Management and Technology (IDOPMT)Semester 1 8 – 24 Mar

MPOB HQSemester 2 6 – 30 AprEstate Attachment 4 – 8 MaySemester 3 11 May – 1 Jun

A1.3 Kursus Operator Mekanisasi Ladang (KOML)Tahap 2 Apr (5 bulan) PLASMA Keratong, Pahang

Tahap 3 Okt (5 bulan) PLASMA Keratong, Pahang

A1.4 Kursus Pengurusan dan Penyelenggaraan Nurseri SawitBil. 1: Wilayah Sarawak 24 – 25 Mac *Bil. 2: Wilayah Sabah 14 – 15 Apr PLASMA Lahad Datu, SabahBil. 3: Wilayah Timur/Selatan 12 – 13 Mei Jerantut Hill, PahangBil. 4: Wilayah Utara 25 – 26 Ogos *Bil. 5: Wilayah Tengah 20 – 21 Okt Putin Resort, Melaka

CODE NO. TITLE DATE VENUE

A COURSES 1 OIL PALM

A1.1 Kursus Kemahiran Menggred Buah Sawit

Bil. 1: Wilayah Utara 24 – 26 Mac Hotel Legend Inn, Taiping, Perak

Bil. 2: Wilayah Tengah 14 – 16 Apr Hotel Melang Inn, Kuala Pilah, Negeri Sembilan

Bil. 3: Wilayah Sabah 21 – 23 Apr Hotel MB, Tawau, SabahBil. 4: Wilayah Timur 26 – 28 Mei Hotel Tanjong Vista, Kuala

Terengganu, TerengganuBil. 5: Wilayah Sarawak 2 – 4 Jun Hotel RH, Sibu, SarawakBil. 6: Wilayah Selatan 9 – 11 Jun Hotel VIP, Segamat, JohorBil. 8: Peperiksaan (Semenanjung) 28 Okt *Bil. 9: Peperiksaan (Sabah) 18 Nov *


For enquiry or further information, please contact:

HRD & Conference Management UnitTel. No. : 03-8769 4400 ext. 4865, 4860, 4867Fax No. : 03-8925 7549E-mail : [email protected]’s website : www.mpob.gov.my

All information are correct as at press time.

Training & Seminars

Note: *To be confirmed.

2 PALM OILA2.1 Diploma in Palm Oil Milling

Technology & Management (DIPOM)Semester I 9 – 18 Mar

MPOB HQSemester II 27 Apr – 7 MaySemester III 8 – 17 JunExamination 7 – 8 Sep

A2.2 The 29th MPOB Oil Palm Products Surveying Course

10 – 14 Aug *

A2.3 The 28th MPOB Oil Palm Products Surveying Examination

Oct* *

A2.4 Kursus Penyelia Kilang Sawit

Peperiksaan

21 – 25 Sep

23 Nov

PLASMA Lahad Datu, Sabah

A2.5 Kursus Pengendali Makmal Kilang Sawit 8 – 16 Jun MPOB HQA2.6 Kursus Kemahiran dan

Pengetahuan Asas Rawatan Tertiari Efluen SawitWilayah SemenanjungWilayah SabahWilayah Sarawak

9 – 11 Feb11 – 13 Mei19 – 21 Okt

PLASMA Keratong, PahangSabah

Sarawak

A2.7 Margarine Course * MPOB HQA2.8 Kursus Penyelia Bengkel Kilang Sawit 8 – 16 Nov MPOB HQA2.9 Kursus Drebar Enjin 2 – 6 Nov PLASMA Lahad Datu, Sabah

B MPOB CONFERENCES AND SEMINARS

1 Palm Oil Economic Review and Outlook 19 Jan The Royale Chulan Kuala Lumpur

2Seminar on Oryctes Nudvirus (OrNV) for Management of Rhinoceros Beetle, Oryctes rhinoceros

28 Jan MPOB HQ

3 PAC Seminar 16 Apr MPOB HQ4 TOT Seminar 8 – 9 Jun MPOB HQ5 GSAS Seminar 19 Jun MPOB HQ6 PIPOC 2015 6 – 8 Oct KLCC, Kuala Lumpur


Feature Article

* Malaysian Palm Oil Board, 6 Persiaran Institusi, Bandar Baru Bangi, 43000 Kajang, Selangor, Malaysia.

E-mail: [email protected]

Note: ** Some parts of the articles were extracted from newspaper reports and Wikipedia.

T

Malaysia’s Entry to Ultra Supercritical Boiler Technology Club**

N Ravi Menon*

INTRODUCTION

his write-up will be of interest to our steam engineers working in all palm oil mills in Malaysia as well as in In-

donesia. Perhaps this will inspire the mill owners to consider improving their current dated technology they are holding tight to high-tech boiler technology for their mill boilers. This technology is not new as it is a common knowledge for mechanical engineers that at high superheat tempera-tures the specific steam consumption will be low resulting in high boiler efficiency. At high boiler pressures and the correspond-ing steam temperatures, the boiler tubes will have to be made of costly alloy steel as the normal steel has its limitations to withstand the high gas temperatures prevailing in the boiler furnace. This is equally true for high altitude jet propelled fighter aircraft gas turbines whose ability to withstand the gas temperature of the hot gases determines its performance during combat operations.

For those who are not familiar with the super critical pressure, the best way to understand it is to look at the temperature-entropy diagram for steam. The steam flow will not cross the diagram but will move upwards towards the critical pressure point above the bell shaped curve; the water and steam becoming a homogenous mixture with no wet region as you would expect when crossing the temperature-entropy curve below its apex.

Malaysia can be proud to be the only country in South-east Asia to own a high technology-based thermal power station by October 2017. The United States, Europe and some countries like Japan, India and China have a number of them in operation. It is quite sensible that most of the new power stations built around the world are now adopting the ultra super critical pressure boilers for their power plants. The thermodynamic possibility of such a technology is not something new to the mechanical engineers as a simple sketch of the temperature entropy curve indicating the path of the steam flow when its pressure and temperature is raised at the supercritical region would indicate that the steam does not have to go through the


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wet region to pick up the latent heat. Now the technology can be translated into actual power plant as boiler tubes made of special alloy steel that can withstand high furnace gas temperatures are within the reach of most of the developing nations.

The palm oil mills can also join the band-wagon as any boiler using fossil fuel or bio-mass can be catapulted to the supercritical pressure regions by modifying the boilers. The can happen only if there is a paradigm shift by the local boiler manufacturers by changing their focus from one that caters for the processing requirement to one that focuses on power generation as the main thrust. This reasons are not difficult to com-prehend.

THE BOILER MAKER’S CHOICE – HIGH TECHNOLOGY OR LOW

TECHNOLOGY

The boiler makers need to wake up to the realities of what the mills will need in the near future. Currently, everything looks bright as the boiler sales are good and profit margin is attractive. If mills can make more profit by selling the electricity than palm oil, the shift to fuel efficient boilers can be expected any time now. The sugar industry, as we are aware, makes more profit out of power production than the sale of sugar it-self. But we need efficient boilers to cater for power plants. The specific steam con-sumption for power generation in a palm oil mill is very high and it is not sensible to consider power generation with such a high steam consumption of 25 kg per kWhr. The local boiler manufacturers should consider modifying their boilers for producing high pressure steam at high superheat tempera-ture, preferably supercritical temperatures.

None of the boiler manufacturer’s in Malaysia appear to be ready to cater for our present boiler requirement or even future requirement. In order to express it in sim-ple language, we are not producing steam at the right pressure and temperature for us to venture into serious power production. If

we get only 1 MW now from the available steam, we can double or triple it by super-heating the same steam. For that we need high pressure boilers that may cost more due to the need for special alloys for mak-ing the boiler tubes. If we do not go for high technology boilers, we may not make much progress in power generation. The boiler makers must make the right move if they want to remain competitive.

THE PRESENT MILL SET-UP vs. THE FUTURE NEEDS

The present power generation is based on the concept of generating steam at 20 barg or 30 barg and admitting this in the steam turbine where it expands to 3 barg pressure (performing a Rankine cycle). It uses about 25 kg steam to generate 1 kWhr energy. However, some manufacturers claim that the specific steam consumption of their turbines is 17 kg. In this case, the saturated steam temperature at 20 barg is 214.7°C. If this is superheated to 500°C, the specific steam consumption can be reduced consid-erably. By superheating the steam, it may be possible to generate 4 MW power from a 60 t hr-1 mill. We can design many configura-tions and after calculations can opt for the most suitable one. One such configuration (not necessarily the best choice) is shown below:

Basic requirement to be satisfied in production of process steam: 60 x 0.6 = 36 t hr-1

Boiler pressure 65 barg, 60 t hr-1 superheated steam at 550°C (280°C super heat). (i) High pressure multi-stage non-condensing turbine with steam flow rate of 60 t hr-1 at 65 bar, exhaust at 30 bar followed by reheating 30 t hr-1 steam to 45 bar and admit in (ii) intermediate pressure multi-stage condensing turbine exhausting at 0.5 bar, (iii) the remaining 30 t hr-1 steam: admit in a non-condensing turbine and exhaust at 3 bar for process heating. The bleed off steam also can be used for process heating. Final condensate to be 30 t hr-1. The process flow is shown in Figure 1. The configuration


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given in Figure 1 is only an example. A number of thermodynamic calculations have to be conducted before confirming that it can give the desired output.

During the expansion in the multi-stage condensing turbine, the bleed-off steam can be used for process heating. It may also be possible to go to high boiler pressures (say 65 bar) and reheat the steam after its expansion in the high pressure turbine to intermediate pressure followed by medium pressure multi-stage turbine at 40 barg exhausting at 0.5 barg.

Probably, we should modify our existing power station by replacing the existing boilers with high pressure boilers and turbines. The power station to be located at Manjung in Perak will have high technology boilers generating steam at high ultra critical pressure and superheat so that the thermal efficiency of the power plant will be close to 46% almost double that of the conventional boilers.

MALAYSIA’S FIRST HIGH TECHNOLOGY POWER PLANT

The new power plant is being constructed next to the existing power plant, in Perak, 10 km south of the nearest town Lumut, ap-proximately 288 km north of Kuala Lumpur and close to the tourist island of Pangkor. It will be the first coal-fired power plant in Malaysia using supercritical technology and the single largest unit in South-east Asia. The estimated cost of the whole pro-ject is RM 5.5 billion (1 billion Euro). This is a sensible move by TNB as the same amount of fuel will be capable of generat-ing double the power output.

CONTRACTOR CONSORTIUM

The contract for engineering, procurement and construction (EPC) has already been signed by TNB-owned Western Energy Bhd (TWE) with a consortium of four com-panies to develop a 1000 MW coal-fired power plant in Perak. The consortium com-

Figure 1. An example of a power plant cum process heating configuration.

STEAM BOILER550o (Super heated)

65 bar, 60 t hr-1

Condenser

IP Turbine 50-0.5 bar

REHEAT to 50 bar

HP turbine 65 bar

36 t hr-1 steam24 t hr-1 steam

24 t hr-1 steam

LP. 30 bar to 3 bar.36 t hr-1 steam


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prised Sumitomo Corporation, Daelim Industrial Co. Ltd, Sumi-Power Malaysia Sdn Bhd and Daelim Malaysia Sdn Bhd. TWE is a unit of TNB Manjung Five Sdn Bhd, a wholly-owned subsidiary of TNB.

The consortium will be responsible for the design, supply, construction and commissioning of the coal-fired thermal powers station that is targeted to be in operation by 1 October 2017. The new power plant will utilise the ultra supercritical boiler technology that is more efficient than current conventional boilers operating in Malaysia. The ultra super-critical boiler technology will also reduce the carbon dioxide emissions.

Astrom and its consortium partners have signed the contract for RM 3.575 billion with TNB’s Janamanjung Sdn Bhd. Astom’s share in this contract amounts to €830 million.

The plant is expected to be online in 2015 providing an extra 1000 MW of power to the Malaysian grid. This power plant is reported to be Astrom’s second project in Malaysia following TNB’s 1999 contract with them to build the 2100 MW Manjung coal-fired power station comprising three 700 MW turbo alternator units, which came into operation in 2004.

The emissions at the plant will be significantly reduced through the use of low NOx burners, a highly efficient seawater flue gas sulphur removal facility and fabric filters to lower nitrous oxide, sulphur oxide and dust emissions. Additionally, Alstom will also supply and install its latest ALSPA® Series 6 Distributed Control System.

FEATURES

Up to an operating pressure of around 190 bar (2755 psig) in the evaporator part of the

boiler, the cycle is subcritical. This means, that there is a non-homogeneous mixture of water and steam in the evaporator part of the boiler. In this case, a drum-type boiler is used because the steam needs to be sepa-rated from water in the drum of the boiler before it is superheated and led into the tur-bine. Above an operating pressure of 221 bar (3205 psig) in the evaporator part of the boiler, the cycle is supercritical. The cycle medium is a single-phase fluid with ho-mogeneous properties and there is no need to separate steam from water in a drum. Once-through boilers are therefore used in supercritical cycles.

SUPERCRITICAL STEAM PRESSURE

The power plants with supercritical pres-sures are designed to operate at about 300 bar and 600°C capable of operating with 46% efficiency compared to 23% for super-heated steam operating at below 450°C. In addition, they have lower emissions than the subcritical power plants. The other ad-vantages are:

• reduced fuel costs due to improved plant efficiency;

• significant reduction in CO2 emissions;• excellent availability, comparable with

that of an existing subcritical plant;• plant costs comparable with subcritical

technology and less than other clean coal technologies;

• much reduced NOx, SOx and particulate emissions;

• compatible with biomass co-firing;• can be fully integrated with appropriate

CO2 capture technology; and • in summary, highly efficient plants

with best available pollution control technology will reduce existing pollution levels by burning less coal per megawatt-hour produced, capturing the vast majority of the pollutants, while allowing additional capacity to be added in a timely manner.


PROJECT FEATURES

The Manjung 4 Project will have the follow-ing high technical components:

• one two-pass, ultra-supercritical, once-through PC boiler (tangential firing low NOx combustion system);

• one STF100 steam turbine with one high-pressure, one intermediate-pressure;

• two double-flow low pressure turbines for high efficiency and reliability;

• one two-pole GIGATOP turbo-generator with the most advanced water/hydrogen-cooling technology for generators, providing high efficiency, outstanding reliability and simple maintenance;

• Alstom’s latest ALSPA® Series 6 Distributed Control System;

• environmental control systems (seawater flue gas desulphurisation and pulse jet fabric filter) to reduce flue gas emissions;

• the Manjung 4 ultra supercritical, higher steam parameters will result in a reduction in operational costs;

• fourteen percent more power generated per tonne of coal burned, compared to the existing Manjung wide range of coal quality Manjung 4 unique TSF 2000 firing system enables to burn a wide range of coal, either bituminous and sub-bituminous >90% SO2 removal;

• Manjung 4 benefits from the seawater flue gas desulphurisation system, designed to treat the complete flue gas;

• reducing cost of electricity, increasing flexibility and reliability lowering environmental footprints; and

• particulate emissions: more than 99% of particulate dust is removed via an electrostatic precipitator (ESP).

ALLOY STEELS

Currently, for once-through boilers, operat-ing pressures up to 300 bar (4350) represent the state-of-the-art. However, advanced steel types must be used for components such as the boiler and the live steam and hot reheat steam piping that are in direct

contact with steam under elevated condi-tions. Therefore, a techno-economic evalua-tion is the basis for the selection of the ap-propriate cycle parameters. Figure 2 depicts the schematic diagram of a pressure power plant.

STEAM CONDITIONS

Most nations are now considering the installation of ultra supercritical pressure boilers in their new power stations to improve their power generation efficiency. Today’s state-of-the-art in supercritical coal fired power plants permit efficiencies that approaches even 50% that is more than double that of yester-years. This means the fuel currently used for power generation can produce double the output using the new technology. Options to increase the efficiency above 50% in ultra supercritical power plants rely on elevated steam conditions as well as on improved process and component quality.

Steam conditions up to 300 bar (4350 psig)/600°C/620°C are achieved using steels with 12% chromium content. Up to 315 bar/620°C/620°C is achieved using austenite, which is a proven, but expensive material. Nickel-based alloys, e.g. inconel, would permit 350 bar/700°C/720°C, yield-ing efficiencies up to 48%. Manufacturers and operators are cooperating in publicly sponsored R&D projects with the aim of constructing a demonstration power plant of this type.

Other improvements in the steam cy-cle and components can yield a further 3% points rise in efficiency. Most of these technologies, like the double re-heat con-cept where the steam expanding through the steam turbine is fed back to the boiler and re-heated for a second time as well as heat extraction from flue gases have already been demonstrated. However, these tech-nologies are not in widespread use due to their cost.

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Figure 2. Schematic diagram of the supercritical pressure power plant.

SUPERCRITICAL REGION. 300BAR, 600oC (1)

Temperature-entropy chart for supercritical pressure power plant.

BOILER

PUMP

BOILER

CONDENSER

HP TURBO-GENERATOR

IP TURBO-GENERATOR

LP TURBO-GENERATOR

CONDENSER

2

HP TURBINE RE-HEAT

LP TURBINE

IP. TURBINE

BOILER FEED PUMP

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THE TEMPERATURE-ENTROPYDIAGRAM

The most exciting part of the ultra super-critical boiler is the diagram that shows how the steam pressure line circumvent the bell curve and settle at the top without crossing the wet steam region. This is done by pressurising the feed water that causes a gradual rise of pressure to 351 bar followed by constant pressure heating in the boiler to attain a temperature of 700°C. If this steam is subjected to isentropic expansion in a steam turbine, the Rankine cycle will cross the temperature-entropy curve in the mid-dle, which being a very wet area will cause considerable damage to the turbine blades. Perhaps a few re-heat stages will enable the low pressure end of isentropic expansion line to settle close to the steam saturation curve. The intermediate pressures can be at 70 bar.

TURBINE GENERATOR SET

There are several turbine designs avail-able for use in supercritical power plants. These designs need not fundamentally dif-fer from designs used in subcritical power plants. However, due to the fact that the steam pressure and temperature are more elevated in supercritical plants, the wall-thickness and the materials selected for the high-pressure turbine section need recon-sideration. Furthermore, the design of the turbine generator set must allow flexibility in operation. While subcritical power plants using drum-type boilers are limited in their load change rate due to the boiler drum (a component requiring a very high wall thickness), supercritical power plants us-ing once-through boilers can achieve quick load changes when the turbine is of suitable design.

High-pressure Turbine (HPT)

In this section, the steam is expanded from the live steam pressure to the pres-sure of the re-heat system, which is usually in the order of 40 bar to 60 bar. In order to

cater for the higher steam parameters in su-percritical cycles, materials with elevated chromium content, which yield higher ma-terial strength, are selected. The wall thick-ness of the HP turbine section should be as low as possible and should avoid massive material accumulation (e.g. of oxides) in or-der to increase the thermal flexibility and fast load changes.

Intermediate-pressure Turbine (IPT)

The steam flow is further expanded in the IPT section. In supercritical cycles, there is a trend to increase the temperature of the re-heat steam that enters the IPT section in order to raise the cycle efficiency. As long as the re-heat temperature is kept at a moderate level (approximately 560°C), there is no significant difference between the IPT section of a supercritical plant and that of a subcritical plant.

Low-pressure Turbine (LPT)

In the LPT section, the steam is expand-ed down to the condenser pressure. The LPT sections in supercritical plants are not different from those in subcritical plants.

ONCE-THROUGH BOILER

Apart from the turbine generator set, the boiler is a key component in modern, coal-fired power plants. Its concept, design and integration into the overall plant consider-ably influence costs, operating behaviour and availability of the power plant.

Once-through boilers have been fa-voured in many countries, for more than 30 years. They can be used up to a pressure of more than 300 bar without any change in the process engineering. Wall thicknesses of the tubes and headers are designed to match the planned pressure level. At the same time, the drum of the normal water tube boiler, which is very heavy and located on the top of the boiler, can be eliminated. Since once-through boilers can be operated at any steam pressure, variable pressure

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operation was introduced into power plants at the start of the 1930s to make the opera-tion of plants easier.

Once-through boilers have been designed in both two-pass and tower type design, depending on the fuel requirements and the manufacturers general practice. For the past 30 years, large once-through boilers have been built with a spiral shaped arrangement of the tubes in the evaporator zone. The latest designs of once-through boilers use a vertical tube arrangement.

OTHER CYCLE COMPONENTS

A comparison of the water-steam cycle equipment in subcritical and supercriti-cal coal fired power plants shows that the differences are limited to a relatively small number of components, i.e. to the feed wa-ter pumps and the equipment in the high- pressure feed water train, i.e. downstream of the feed water pumps. These components represent less than 6% of the total value of a coal-fired power plant.

HIGH EFFICIENCY AND MORE RELIABILITY

Operational Issues

More than 400 supercritical power plants are operating in the US, Europe, Japan, China and India. Availability of supercritical plants is equal or even higher than those of comparable subcritical plants. There are no operational limitations due to once-through boilers compared to drum type boilers. In fact, once-through boilers are better suited to frequent load variations than drum type boilers, since the drum is a component with a high wall thickness, requiring controlled heating. This limits the load change rate to 3% per minute, while once-through boilers can step-up the load by 5% per minute. This makes once-through boilers more suitable for fast start-up as well as for transient conditions.

Fuel Flexibility is not Compromised in Once-through Boilers

All the various types of firing systems (front, opposed, tangential, corner, four wall, arch firing with slag tap or dry ash removal, fluidised bed) used to fire a wide variety of fuels have already been imple-mented for once-through boilers. All types of coal as well as oil and gas have been used. The pressure in the feed water system does not have any influence on the slagging behaviour as long as steam temperatures are kept at a similar level to that of conven-tional drum type boilers.

Life Cycle Costs of Supercritical Coal Fired Power Plants

Current designs of supercritical plants have installation costs that are only 2% higher than those of subcritical plants. Fuel costs are considerably lower due to the in-creased efficiency and operating costs are at the same level as subcritical plants. Specific installation cost, i.e. the cost per megaWatt decreases with increased plant size. Some of the latest installations in China that had been making headlines recently are given below:

Yuhuan 1000 MW ultra supercritical pressure boilers, China. All four 1000 MW coal-fired ultra supercritical pressure boilers at Yuhuan in China have come online. Located on the coast of east China’s Zhejiang Province, the last unit began commercial operation in November 2007. The plant cost ¥ 9.6bn (€ 900m), and the units run at about 45% efficiency. Yuhuan has China’s first 1000 MW ultra supercritical pressure boilers. Units 1 and 2 went online in 2006, and Units 3 and 4 in 2007. The site is now generating 22 billion kWhr of electricity a year. The plant is operated by China Huaneng Group, China’s largest power producer. It is claimed that Yuhuan Units 1 and 2 are the world’s cleanest, most efficient and most

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advanced ultra supercritical units. When Unit 4 is working, the site will generate 22 billion kWhr of electricity a year.

Ultra supercritical pressure boilers. Supercritical operation of large thermal baseload power plants during the 1980s used steam temperatures of typically 550ºC, leading to around 40% thermal efficiencies. Ultrasupercritical steam conditions now use supercritical pressures up to 300 bar, with 600°C steam and re-heat steam temperatures. This gives a net efficiency of 46%.

Siemens reports that just a 1% gain in efficiency for a typical 700 MW plant reduces 30-year lifetime emissions by 2000 t NOx, 2000 t SO2, 500 t particulates and 2.5 million tonnes CO2.

New units also incorporate high effi-ciency dust removal and desulphurisation. This has led to the claim that Yuhuan Units 1 and 2 are the world’s cleanest, most effi-cient and most advanced ultra supercritical units.

The MHI boilers have a main steam pressure of 27.5 MPa, a main steam temperature of 605°C and a re-heat steam temperature of 603°C. The boilers were made and commissioned collaboratively by MHI in Japan, which provided the designs and key products, and Harbin Boiler Co. (HBC) in China. Unit 4 was constructed by MHI and HBC. MHI plans to supply above 12 GW of boilers to China under the HBC collaboration.

Siemens is supplying four 1000 MW ultra supercritical steam turbines. These use a tandem compound, four-cylinder arrangement. Steam enters the high-pressure turbine through two main steam valves, with exhaust steam being re-heated and fed to a double-flow intermediate-pressure turbine. From there, it goes to two low-pressure turbines. The steam turbines at the Yuhuan power plant were jointly designed and manufactured by Shanghai Electric Group and Siemens Power Generation Group.

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* Malaysian Palm Oil Board, 6 Persiaran Institusi, Bandar Baru Bangi, 43000 Kajang, Selangor, Malaysia. E-mail: [email protected]

T

A Critical Look at the Palm Oil Operations

N Ravi Menon*

INTRODUCTION

his article is a repeat of the article previously published. As I felt that it contains some important points

that will not get dated anytime in the near future, the millers are requested to read it through to improve the milling activity in their mills. The fabricating industry should also be well versed with what the millers seek so that they can fabricate machinery to fulfil the requirements of the industry.

FOCUS AREAS

The following tips are intended to direct the attention of the process engineer or the mill manager on the often neglected relatively obscure corners of the process flow system. A thorough knowledge of the intricacies associated with it would make processing operation more scientific and extraction rate more profitable. An engineer or for that matter a process supervisor, who take the trouble to grasp the fundamental ba-sics, would be able to perform better than others, who lack the knowledge, provided

of course, the infrastructure like the pro-cess control laboratory and the process op-erators are reliable and committed. Let us now look at all the process areas including the hidden areas of the processing plant. Only two of them play a significant role, are highlight: (a) process control dilemma and (b) practical actions for controlling product losses.

WEAKNESS IN PROCESS CONTROL SYSTEM

The analysis of samples provides the evi-dence of whether the processing had been efficient or otherwise. But do they really represent the actual processing? Can any mill engineer honestly declare that his mill laboratory analysis give a good indication of the actual operation of his mill? No mat-ter how accurate the analysis, the result be-comes meaningless if the sampling is errat-ic. Who checks on the sampling and how it is being performed? Do they follow all the guidelines all the time? Let us look at them critically.

OIL LOSS IN STERILISER CONDENSATE

The steriliser condensate flows into the steriliser condensate pit and from there it is pumped out separately into the final


Feature Article

effluent pit. After this, no oil is pumped into the process system as it is deemed to be off-quality. How a representative sample is to be taken from this pit is a big question mark as the oil usually floats in the pit but small particles will not rise to the surface. If we take a mixture of samples from the top and the bottom will it be a representative sam-ple? Some mills have solved the problem by pumping the top layer of the condensate oil for press crude oil dilution. Does this mean that there is no more oil loss here? This un-ethical practice has almost become a regular feature now, encouraged by the lucrative crude palm oil price.

OIL LOSS IN EMPTY FRUIT BUNCH

It is almost impossible to obtain a repre-sentative sample from empty fruit bunch. Here, bunches will have varying degrees of oil content depending on the degree of ripe-ness and the threshing they are subjected to. The oil loss may vary widely and even can reach 1% (% to fresh fruit bunch) but such high figures are usually rejected by the mill as an odd figure. The sampling method is also some what odd. Usually one bunch is selected from every 300 bunches mov-ing along the conveyor and if that hap-pens to have absorbed the least oil, the oil loss in empty fruit bunch will be low for a prescribed period of time. This trial is con-ducted once in every six months or none at all. Those who do not conduct this trial adopt an arbitrary figure close to 0.45% (% to fresh fruit bunch) as a normal value, even though the actual loss could be as high as 0.6% (% to fresh fruit bunch) or even more. Some mills do not consider this as a loss at all, when computing total oil loss to fresh fruit bunch. Empty fruit bunch is like a bloating paper and it really absorbs oil - probably more than any other bunch com-ponent – yet the least importance is given to it. This is a vast contrast to the oil ab-sorbed by the nut surface at only 0.08% (% to fresh fruit bunch) for which more atten-tion is given by the process control and the mill management.

It is difficult to give a figure that will re-flect the actual oil loss in empty fruit bunch-es with reasonable degree of accuracy to satisfy a serious process engineer. A simple and practical compromise seems to be to conduct trials at least once a month super-vised by the process engineer.

OIL LOSS IN CYCLONE FIBRE

The cyclone fibre (mesocarp fibre) may be defined as the lignin components of the press cake containing, when fresh, some residual oil and moisture with nuts at a slightly lower proportion by weight in the press cake. As no mechanical processes can extract all the juice from the mesocarp it is important to handle the pressing operation with considerable care to ensure that the two vital process-sensitive parameters are under good control. They are: (a) the resid-ual oil in the mesocarp fibre and (b) the nut breakage.

In most mills, sufficient attention is not given to these important requirements. Some process operations and the corre-sponding results are tabulated in Table 1.

The moisture and the oil content in the fibre can vary if wrong process option is chosen. The accuracy of sampling can play a vital role in the accuracy of the results. In fact, the majority of the mills may fall un-der this category in the absence of external process audits. The samples taken from the bottom of the press are usually oily, while that of the top are dry. The oil loss can vary widely in both samples. The accuracy in such cases will depend on a proper mixing and quartering of samples.

PRACTICAL ACTIONS FOR CONTROLLING PRODUCT LOSSES

Sterilisation

The steriliser temperature has to remain high, preferably above 140oC for a number of reasons. The mill engineers are fully

See page 31


Feature Article

TABLE 1. SOME COMMON OPERATIONS AND THEIR CONSEQUENCES

Common operations Options Digester(oC) Results

Poor digester drainage Low pressing pressure A > 90 High nut breakage often exceeding 15%

Oil loss in fibre also will be high

Poor digester drainage High pressing pressure B > 90 High nut breakage often exceeding 15%

Oil loss in fibre also will be high

Good digester drainage High pressing pressure C > 90 High nut breakage often exceeding 15%

Low oil loss in fibre

Good digester drainage Low pressing pressure D > 90 Low nut breakage

Low oil loss in fibre

Good digester drainageLow pressing pressure E <85 Low nut breakage

High oil loss in fibre

Poor digester drainageHigh pressing pressureLow digester temperature

F <85High nut breakageHigh oil loss in fibre

aware of this. The main reason is not steri-lisation per se as that will require only 60oC

for a few minutes to inactivate lipase but for conditioning the pericarp and nuts for sub-sequent process activities. The correct ter-minology for this is pressure cooking.

Impact of De-aeartion

Admitting 3 barg steam into the sterilis-er, while half of it still contains air will not give satisfactory cooking. If for example, it contained one-quarter air and three-quarter steam, the partial pressure of steam, ac-cording to Daltons Law of Partial Pressure is only 2 barg and the corresponding satu-ration temperature will be based on 3 bara, i.e. 133.5oC instead of 143.6oC expected of steam at 4 bara. The 10° difference is signifi-cant in terms of fruit conditioning and oil loss.

Proper Sterilisation

If serious attention is given to remove as much air as possible from the steriliser chamber, mills will not have to install dou-ble stripping. If bunches are heated to a temperature that is above 140oC, fruits will

detach from the bunch without the need for double stripping. Air is continuously re-leased by the bunch, when it is subjected to heating and its evacuation is accomplished by the continuous bleeding of the conden-sate. Double stripping is akin to fighting consequences rather than the cause.

Clarification Oil temperature

The clarification tank temperature has to be close to or above 90oC, if high oil extrac-tion rate is the priority. But unfortunately, at high process temperatures, the DOBI value will drop. A compromise has to be made here. The difference in oil extraction rate can be quite significant when processing at high or low temperatures.

Press Cone

There is no established data on the ef-fectiveness of the mild steel plate that now seem to have replaced the once popular conical plug, for constraining the free dis-charge of press cake. In all likelihood, the conical plug could get better results than a flat plate as in the former case, the press cake can flare out evenly.

see page 26


Feature Article

Digester Drainage

The press feed should not contain too much oil as this will cause the feed to be slippery. On the other hand, if most of the oil has been pre-extracted, then with low pressing pressures, the remaining oil can be extracted. There is no benefit in increasing the press cone pressure indiscriminately to excessive pressures like 60 - 80 bar with the intention of extracting more oil. What will generally happen is very high nut breakage, which should not be permitted to exceed 15%. In their eagerness to increase the oil extraction rate, some mills resort to even 80 bar cone pressure without any considera-tion for excessive nut breakage. Consider-able oil can be drained off from the digest-er by installing a good drainage box that works under all conditions.

Pressing Pressure

Using high cone pressure in a press would also cause an increase in the produc-tion of solids that in turn will absorb oil. For improving oil separation in the digester, a few fundaments have to be adhered to. They are: (a) the digester must be at least three-quarter full, (b) the temperature must be at least 95oC, (c) the digester tip clear-ance should be a minimum and (d) the in-ter-blade vertical constraint bars on the in-side digester chamber wall must be in place as without which digester will not be effec-tive.

Crude Oil Dilution

The crude oil extracted by the press by itself is ready for clarification without any water dilution as at virgin state the mois-ture level in the crude palm oil is ideal hav-ing the least viscosity with ideal separation properties. Dilution is carried out primar-ily for promoting the flow of crude palm oil through the gutter into the vibrating screens as otherwise it is too thick to flow. This could have been resolved by install-ing an auger to push it through the gutter but an erratic step was initiated then and to this day it holds good as an integral process

step. The current water addition regime is about 41% of the press liquor so that the fi-nal oil content in the diluted crude is 39% from the original 55% in crude oil.

Crude Oil Pump

The crude oil transportation from the crude oil tank to the clarification tank origi-nally was done using a positive displace-ment screw pump like Mohno pump. Now almost all mills have shifted to centrifugal pumps because they are cheap and easy to maintain. But its defects, for pumping crude oil, are not well publicised. The churning effect of the centrifugal pump causes the formation of emulsion, which once formed, remains inseparable from one another. That is why, for maximum oil recovery, positive displacement pumps were recommended. The sub-micron oil droplets generated by the centrifugal pumps are too small to pos-sess sufficient buoyancy to rise in the clari-fication tanks and they will easily find its way to the effluent stream without being captured by the sludge centrifuge.

Rotary Brush Strainer

Another equipment that seem to have gone out of fashion is the rotary brush strainer, which has a real function to play. It imparts a shearing force to the sludge so that oil separation in the separator is more efficient. It should not be trimmed to make rotation easy within the brush chamber as which in case it will not be serving any purpose at all.

Sludge Separator

Simple logic says that the smaller the nozzles the better oil recovery or inversely when the nozzle size enlarges the oil loss will tend to rise. The separator also must run full for good oil recovery. This can be done by having a ring type sludge header that can supply feed to all separators equal-ly so that no separator will be subjected to partial starvation. These are reasonably well established factors which most millers are likely to be well-versed.


Feature Article

Impact of Excessive Dilution

Apart from the above, it is important to recognise the volume of sludge that the sludge separators are required to handle. If the oil losses ex-sludge centrifuge is x%, it will not change if the sludge feed is diluted excessively or otherwise, i.e. if 100 litres of sludge is fed into the separator and the oil loss in the discharge outlet is 0.6%, it will remain the same. If the sludge is diluted 100% and the volume has now become 200 litres. In both cages, percentage oil loss will remain the same but the absolute oil loss will become double. By dilutions the % oil retained by the waste water is not reduced. Hence, dilution will actually promote oil loss.

KERNEL LOSSES

De-pericarp Column Setting

The fibre/nut separator or the de-peri-carp column as it is popularly known can contribute significantly towards the loss of kernel, simply because the adjustable velocity of the separating column is set er-ratically and no one has the equipment to measure it. The mill only has to make an opening in the ducting to insert the measur-ing instrument that can give the velocity of air flow within the column that ranges from 12.5 to 15 m-1. By careful adjustments, the optimum velocity suitable for the cracked mixture could be selected by adjusting the throat area of the separating column.

Separation Velocity

The exercise should be carried out on a routine basis so that there is no deviation of separating velocity for prolonged periods of time as the losses could then be significant. At least there should be a weekly velocity monitoring instead of the present once in a lifetime measurement and this can be done and recorded by the process assistant or the plant operator. The throat velocity can vary due to many reasons like fan blade erosion, accumulation of fibre inside the ducting of the chute or even a puncture along the

product flow line. The measurement will throw some light on any of the defects that could have developed during processing due to one reason or other. As the gains far outweigh the investment cost of RM 600 to RM 800 for the purchase of this equipment, millers are encouraged to consider the pur-chase of one such equipment.

NUT LOSSES IN CYCLONE FIBRE

Separation Column Setting

It is common to see small nuts being lift-ed and carried along with the cyclone fibre. While it may not be possible to prevent the flow of all nuts, considerable control of this loss can be achieved if the lifting velocity at the separating column is maintained at an optimum level, to cater for free kernel and large or medium pieces of shell to be held in suspension under the action of the in-duced draft fan. The normal lifting velocity is about 12 m-1 but may vary depending on the size of nuts. This optimum velocity has to be established by trial and error, guided by the free kernel and small nut losses in cyclone fibre and may have to be re-estab-lished again, preferably on a yearly basis. Therefore, it is not a waste to purchase the very useful velocity measuring device.

THE FOUR-STAGE WINNOWING SEPARATION SYSTEM

MPOB initiated dry separation system, now undergoing intensive development work for perfecting the equipment and optimis-ing process parameters, has to depend a great deal on the optimum velocities at many critical points, where separation will take place. Mills using this system will gain maximum benefit if they monitor the lifting velocities at all the required points or oth-erwise kernel losses may take place with-out detection. The dry separation system is targeted to do away with the production of effluent and all mills in Malaysia are ex-pected to adopt it as it offers many positive benefits including better kernel extraction and zero effluent production that no other system can offer.


Titbits

Un-recognised Laws

N Ravi Menon*

Law of Mechanical Repair - after your hands become coated with grease, your nose will begin to itch and you’ll badly want to go for a pee.

Law of Gravity - any tool, nut, bolt, screw, when dropped, will roll to the least acces-sible corner. Law of Probability - the probability of be-ing watched is directly proportional to the stupidity of your act. Law of Random Numbers - if you dial a wrong number, you never get a busy signal and someone always answers.

Variation Law - if you change lines (or traf-fic lanes), the one you were in will always move faster than the one you are in now (works every time). Law of the Bath - when the body is fully immersed in water, the telephone rings. Law of Close Encounters - the probability of meeting someone you know increases dramatically when you are with someone you don’t want to be seen with. * Malaysian Palm Oil Board, 6 Persiaran Institusi, Bandar Baru Bangi, 43000 Kajang, Selangor, Malaysia. E-mail: [email protected]

Law of the Result - when you try to prove to someone that a machine won’t work, it will. Law of Biomechanics - the severity of the itch is inversely proportional to the reach.

Law of the Theater and Hockey Arena - at any event, the people whose seats are far-thest from the aisle, always arrive last. They are the ones who will leave their seats sev-eral times to go for food, beer, or the toilet and who leave early before the end of the performance or the game is over. The folks in the aisle seats come early, never move once, have long gangly legs or big bellies and stay to the better end of the perfor-mance. The aisle people also are very surly folk. The Coffee Law - as soon as you sit down to a cup of hot coffee, your boss will ask you to do something which will last until the coffee is cold. Murphy’s Law of Lockers - if there are only two people in a locker room, they will have adjacent lockers. Law of Physical Surfaces - the chances of an open-faced jelly sandwich landing face down on a floor, are directly correlated to the newness and cost of the carpet or rug.


Titbits

Law of Logical Argument - anything is possible if you don’t know what you are talking about. Brown’s Law of Physical Appearance - if the clothes fit, they’re ugly. Oliver’s Law of Public Speaking - a closed mouth gathers no feet. Wilson’s Law of Commercial Marketing Strategy - as soon as you find a product that you really like, they will stop making it. Doctors’ Law - if you don’t feel well, make an appointment to go to the doctor, by the time you get there you’ll feel better. But don’t make an appointment, and you’ll stay sick.

Ennar’s Law on Crossing Cars - if two face each other coming in opposite directions they will cross where there is an obstacle or another car is passing.

Ennar’s 1st Law on Changing Lane - when you put the signal and change your line to the right, the leading car on that lane even though was far behind you will flash his light from 100 m away and race to prevent you from changing the lane with an expres-sion on his face that seem to say, “how dare you encroach into my lane?

Ennar’s 2nd Law on Changing Lane - if you do not put the signal and change lane the leading car on the right side will not race and you can comfortably change the lane.

Ennar’s 3rd Law on forced Lane Change - the driver, usually in a powerful and expen-sive car wants you out of the lane as your car ( cheap car) does not deserve to be in the fast lane and he races towards your car at top speed with lights flashing as though he intends to have a collision with your car. So you get scared and move out of that lane giving way to him. Ennar’s Law on Rain and Umbrellas - when it is raining heavily and you want to

exit and try to open your folded umbrella it will always open the opposite way and when you get it right your car door interior will be soaked in rain.

Ennar’s Law on TAG - the toll gate will be perfectly functional until the person ahead of you fail to get the gate opened with his TAG card and when you struggle and re-verse to join the back of the Touch and Go gate queue, the TAG gate will become nor-mal.

Ennar’s Law on Traffic Lights - when you are anxiously waiting for your turn to make a right hand turn at the traffic light and the light is about to change to red, the car in front will make a slow U-turn so that you miss the chance to turn right.

COALASCENCE PLATE SEPARATOR

The coalescence plate separator has been around for some time but most palm oil millers seem to be reluctant to try it out in their mills. In Malaysia, palm oil mills will be able to get the maximum benefit best out of it. There has been very little research done on tapping the great potential that this simple device is offering. This machine shown in Figure 1 also has a number of ad-vantages compared to other machines.

• It is easy to fabricate. This can be made in the mill workshop. First fabri-cate the conical bottom steel tank with the inlet compartment. The coalescence plates can be packed as close as possible and it can be hung from the top of the steel tank chamber. This will facilitate easy cleaning of the plates.

• Needs no energy to operate. This is a static machine that does not consume electric or any other energy and as such mills are encouraged to use this ma-chine to separate as much oil as possible form the crude oil or sludge.

• Feed preparation. The feed liquid flow-ing into the machine must allow a lami-


Titbits

nar flow regime in order to allow the oil droplets to rise through the inter-plate gap. The capacity of the machine must match the maximum throughput of the mill. A long channel with a few weirs mounted in it can at inlet section of the channel change the flow from turbulent to laminar flow before the liquid is care-fully fed into the coalescence plate sepa-rator. The inlet section also can remove most of the solids so that there will not

Press liquor

Solid outlet

Figure 1. A simple sketch of a coalascence plate separator.

be too much solids that could clog the separator deck of plates. An undersized separator will not be able to perform well.

• Low maintenance cost.

• Low labour cost.

• Vast research potential.

OIL LAYER

PACKED-AS CLOSE AS POSSIBLE

Oil outlet

Sludge outletDEFLECTOR PLATE

sludge


Datasheet

Power station Location Owner Type MWGas Fired Power Plants

Connaught Bridge Klang, Selangor TNB Combined cycle 832Genting Sanyen Kuala Langat, Selangor Genting Sanyen Combined cycle 720Karambunai Karambunai, Sabah Ranhill Bhd Open cycle 120Lumut GB 3 Pantai Remis, Perak Malakoff Combined cycle 651Lumut P S Pantai Remis, Perak Malakoff Combined cycle 1 303Nur Generation Kulim, Kedah Nur Generation S/B Combined cycle 220Paka P S Paka, Terengganu YTL International Bhd Combined cycle 808Pasir Gudang Pasir Gudang, Johor YTL International Bhd Combined cycle 404Petronas Gas CUF Gebeng-Kerteh,

TerengganuPetronas Gas Bhd Cogen 324

Port Dickson P S Port Dickson, Negeri Sembilan

Malakoff Open cycle 440

Prai Power Station Prai, Pulau Pinang Malakoff Combined cycle 350Putra Jaya P S Serdang, Selangor TNB Open cycle 625Sarawak Power Gen Bintulu, Sabah Sarawak Energy Bhd Open cycle 220Sultan Iskandar P S Pasir Gudang, Johor TNB Combined cycle 729Sultan Ismail P S Paka, Terengganu TNB Combined cycle 1 136Tanjong Kling P S Melaka Powertek (Pehlawan P) Combined cycle 330Telok Gong P S 1 Melaka Powertek Open cycle 440Telok Gong P S 2 Melaka Powertek (Panglima P) Combined cycle 720Teknologi Tenaga Perlis Sungai Baru, Perlis Teknologi Tenaga/global ET Combined cycle 650Tuanku Jaafar P S Port Dickson, Negeri

SembilanTNB Combined cycle 1 500

Sub-total 12 522Diesel Generators

Gelugor P S Teluk Ewa Pulau Pinang TNB Diesel 398Melawa (ARL Tenaga SB) 50 MW, Sandakan P. Corp 34 MW, Startavest 60 MW, Tawau 36 MWa Diesel 180

Sub-total 578Hydro-electric Power

Sultan Azlan Shah, Bersia Bersia, Perak

Sungai Perak Hyd. Scheme

Hydro-electric 72Chenderoh P S Chenderoh, Perak Hydro-electric 40.5Sultan Azlan Shah, Kenering Kenering, Perak Hydro-electric 120Sungai Piah Upper P S Sungai Piah, Perak Hydro-electric 14.6Sungai Piah Lower P S Sungai Piah, Perak Hydro-electric 54Temenggor P S Temenggor, Perak Hydro-electric 348Sultan Mahmud P S Terengganu Sungai Terengganu Bhd Scheme Hydro-electric 400Sultan Ismail Petra P S Pergau, Terengganu Sungai Pergau Hyd scheme Hydro-electric 600Sultan Yusof P S Johor Cameron Highlands

Hydro-electric SchemeHydro-electric 100

Sultan Idris Woh P S Johor Hydro-electric 150Odak, Habu, Kg Raja, Terla, Robinson Fall (4.2+5.5+0.8+0.5+0.9 MW) Hydro-electric 11.9Sungai Perak

21 damsTNB Hydro-electric

1 911Sungai Terengganu TNB Hydro-electricCameron Highlands TNB Hydro-electric

Sub-total 3 822Coal or Combined Gas/Coal

Jimah P S Lukut, Perak - 2ST Jimah Energy Ventures SB Steam turbine 1 400Manjung P S Manjung, Perak - 3 ST TNB Janamanjung SB Steam turbine 2 295PPLS Power Generation Kuching, Sarawak - 2GT PPLS PG, Sabah Energy Bhd Steam turbine 110Sejingkat Power Corporation Kuching, Sarawak - 1 ST Sejingkat PG, Sarawak Steam turbine 100Sultan Salahuddin A. Aziz Shah

Kapar, Selangor - 6ST, 2 GT Kapar Energy Ventures Steam and gas turbine

2 420

Tanjung Bin PS Pontian, Johor - 3 ST Tanjung Bin PSB Malakoff Steam turbine 2 100Sub-total 8 425

Hybrid power station(wind, solar, diesel) : 650 MW; Biomass: about 29 MW) Total: 679 MW 679 Grand total 26 026

POWER GENERATION PLANTS IN MALAYSIA

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ADVERTISEMENTue to the increased cost of printing, the advertisement rate is RM 700 per issue for an A4 size page of black and white, whereas the cost for colour is RM 900. One year of complimentary Vendor’s List advertisement for every one page A4-size colour or black & white advertisement. Advertisers are required to submit to us either their own black and white or colour artwork in CD. Cheque should be made payable to the ‘Malaysian Palm Oil Board’. If you have any queries, please contact the following at MPOB.

Tel: 03-87694400 Fax: 03-89262971

Dr. Lim Weng Soon ext: 4406 • Ir. N. Ravi Menon ext: 4467 • Lim Soo Chin ext: 4676 E-mail: [email protected]

Advertising Schedule for MPOB Palm Oil Engineering Bulletin

Issue Quarter Deadline forRegistration

Deadline forSubmission of Artwork

114 Jan - Mar 2015 30 Jan 2015 28 Feb 2015115 Apr - Jun 2015 30 Apr 2015 31 May 2015116 Jul - Sept 2015 30 Jul 2015 30 Aug 2015117 Oct - Dec 2015 31 Oct 2015 30 Nov 2015

REPLY-SLIP

Dr. Lim Weng Soon/Ir. N. Ravi MenonEngineering and Processing Division Palm Oil Engineering BulletinMPOB6, Persiaran InstitusiBandar Baru Bangi43000 Kajang, Selangor

PALM OIL ENGINEERING BULLETIN ADVERTISEMENT – FULL PAGE ADVERTISEMENT

1. We confirm our intention to advertise in the MPOB Palm Oil Engineering Bulletin.

Company:

Address:

E-mail: Tel. No.: Fax No.: Contact Person: Issue No.:

2. The artwork is attached/will be sent on for your further action.

3. Please find enclosed *crossed cheque No.: for RM ( ) being payment for the advertisement fee.

4. Thank you.

(Signature and Date) (Company stamp)

D# * Made payable to ‘MALAYSIAN PALM OIL BOARD’.


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ollowing a decision by the Editorial Board to further increase the role of Palm Oil Engineering Bulletin to serve the industry better, a new addition called Palm Oil Mill Vendor’s List has been introduced similar to Telekom Yellow Pages to assist mill engineers to know where to source materials or services pertaining to the industry. In order to make this useful, we need the co-operation of the mill engineers/managers to persuade their vendors to advertise in the Vendor’s List for a nominal fee of RM 100/year. If you have any queries, please contact the following at MPOB.

Tel: 03-87694400 Fax: 03-89262971

Ir. Ravi Menon ext. 4467 or e-mail: [email protected] Ms. Lim Soo Chin ext. 4676 or e-mail: [email protected]

REPLY SLIP

Dr. Lim Weng Soon/Ir. N. Ravi MenonEngineering and Processing Division Palm Oil Engineering Bulletin AdvertisementMPOB, 6, Persiaran Institusi, Bandar Baru Bangi, 43000 Kajang, Selangor, Malaysia.

We wish to advertise in the MPOB Palm Oil Engineering Bulletin Vendor’s List

Company: Issue No.:

Contact Person: H/P:

Address:

E-mail: Tel: Fax:

Please find enclosed a crossed cheque No.: Bank:

for RM: (Ringgit Malaysia)

drawn in favour of MALAYSIAN PALM OIL BOARD

Please select the headings from the list given below (not more than five headings) under which you wish to advertise.

Air filters/dryersAir separatorsBearings/belts/bushesBiomass/bio-compost/productsBoiler spares/control/othersBoiler suppliers Bunch crushersCastingsCivil engineering Cleaning - generalCondition monitoringConsultancy services/certificationControl/automation/sparesConveyors/chains/elevators/beltsDiesel eng./services/sparesDynamic balancing Electric motors/systemsExpansion jointsFabrication works Fans

Signature:

Name:

Date: Company stamp

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Filter press/materialsFluid control system/couplingsGaskets/packing materials/sealsGear boxesHardware Hydraulic systems/services/spares Laboratory analysisLaboratory equipmentLubricantsMill machinery/sparesMiscellaneousNut crackersOil recovery systemsPalm kernel oil crushing plantPower plantPollution control/safety systemsPressure vesselsPumps/services PurifiersScrew press/parts

ScrubbersSludge separators/decantersSteam turbines/generator/sparesSterilizer/partsStorage silosVacuum pumpsValves/seatsWaste water treatment Water treatmentWeighing machines/sparesWelding equipmentsWheel loaders/spares


From:

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(We have enclosed this form to assist you in sending to us any questions or comments)

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ChairmanThe Editorial BoardPalm Oil Engineering Bulletin Malaysian Palm Oil Board P. O. Box 1062050720 Kuala LumpurMalaysia

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The grand MPOB International Palm Oil Congress and Exhibition (PIPOC) with five concurrent Conferences will examine and discuss the many facets of the oil palm industry. PIPOC 2013 was attended by more than 2200 participants from 48 countries.

Book your place now to make sure you will be one of them in 2015!

PIPOC 2015 features 5 concurrent Conferences,namely:

• Agriculture, Biotechnology & Sustainability• Chemistry, Processing Technology & Bio-Energy• Food, Lifestyle & Health• Oleo & Specialty Chemicals• Global Economics & Marketing

Another attraction of the Congress isan Evening Forum on Current Issues.

You may opt to be a:SPEAKER, POSTER PRESENTER or PARTICIPANT

or your organisation may:• EXHIBIT your products and/or services• ADVERTISE in the Souvenir Programme of the Congress

6 - 8 October 2015Kuala Lumpur Convention Centre,

Kuala Lumpur, Malaysia

TheMalaysian Palm Oil Boardis organising >>

The Premier Oil Palm Event is back!


After two years, it is timely to update your knowledge and information on the developments in the R&D of oil palm. It will be a platform for participants to interact and share information in all areas pertaining to the oil palm/palm oil industry.

This bi-annual Congress provides a platform that showcases the latest advances in the industry. A grand exhibition with a total floor space of more than 2000 m2 and 300 booths will showcase many new technologies and information to increase the productivity of your business.

Technical tours to an oil palm plantation, palm oil mill, refinery and R&D facilities will also be arranged. A golf tournament is also in store for participants and golf enthusiasts.

So, be part of the event and don’t miss this opportunity to update and get yourself networked.

Mark your calendar and make it known to your friends and colleagues

For more information, please contact: [email protected] or visitMPOB website at www.mpob.gov.my

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Documents

Engineering Bulletin #102 front cover - PALMOILISpalmoilis.mpob.gov.my/publications/POEB/poeb113.pdf · palm oil engineering bulletin no. 113 1 engineering bulletin #102 front cover